Magnesium alloy and production method of the same

ABSTRACT

To provide a magnesium alloy having high incombustibility, high strength and high ductility together. A magnesium alloy including Ca in an amount of “a” atomic %, Al in an amount of “b” atomic % and a residue of Mg, including (Mg, Al) 2 Ca in an amount of “c” volume %, wherein “a”, “b” and “c” satisfy the following equations (1) to (4), and having the (Mg, Al) 2 Ca dispersed therein.
 
3≤ a ≤7  (1)
 
4.5≤ b ≤12  (2)
 
1.2≤ b/a ≤3.0  (3)
 
10≤ c ≤35  (4)

TECHNICAL FIELD

The present invention relates to a magnesium alloy and a production method thereof.

BACKGROUND ART

Mg—Al—Ca alloys have been developed mainly for die-casting materials. In addition, a hard compound is formed by addition of an excessive amount of Al and Ca which are solute elements, resulting in being brittle, and thus excellent mechanical properties cannot be obtained.

Accordingly, although a magnesium alloy in a low addition amount of Al, Ca has been developed, the strength has not yet been improved. In view of the above facts, as to studies of the Mg—Al—Ca alloy, studies of phase to be formed and studies limited to Mg—Al—Ca alloys in an extremely low addition amount of Al, Ca have been carried out.

Furthermore, in order to make the magnesium alloy practical, it is necessary to enhance incombustibility and to raise its ignition temperature. However, since when improving the incombustibility, there are many cases of lowering the mechanical properties, and the incombustibility and the mechanical properties is in a tradeoff relationship, it is difficult to enhance both of the properties.

DISCLOSURE OF THE INVENTION

An object of one aspect of the present invention is to provide a magnesium alloy having high incombustibility, high strength and high ductility together, or a production method thereof.

Hereinafter, various aspects of the present invention will be explained.

-   -   [1] A magnesium alloy:         -   including Ca in an amount of “a” atomic %, Al in an amount             of “b” atomic % and a residue of Mg,         -   including (Mg, Al)₂Ca in an amount of “c” volume %,         -   wherein “a”, “b” and “c” satisfy the following equations (1)             to (4), and         -   having the (Mg, Al)₂Ca dispersed therein.             3≤a≤7  (1)             4.5≤b≤12  (2)             1.2≤b/a≤3.0  (3)             10≤c≤35 (preferably 10≤c≤30)  (4)     -   [2] A magnesium alloy:         -   including Ca in an amount of “a” atomic %, Al in an amount             of “b” atomic % and a residue of Mg,         -   including (Mg, Al)₂Ca in an amount of “c” volume %,         -   wherein “a”, “b” and “c” satisfy the following equations (1)             to (4), and         -   having the (Mg, Al)₂Ca dispersed therein.             3≤a≤7  (1)             8≤b≤12  (2)             1.2≤b/a≤3.0  (3)             10≤c≤35 (preferably 10≤c≤30)  (4)     -   [3] The magnesium alloy according to the above [1] or [2],         -   wherein the magnesium alloy further comprises Zn in an             amount of “x” atomic %, wherein “x” satisfies the following             equation (20).             0<x≤3 (preferably 1≤x≤3)  (20)     -   [4] The magnesium alloy according to any one of the above [1] to         [3],         -   wherein the magnesium alloy further comprises Al₁₂Mg₁₇ in an             amount of “d” volume %, wherein “d” satisfies the following             equation (5).             0<d≤10  (5)     -   [5] The magnesium alloy according to any one of the above [1] to         [4],         -   wherein a crystal particle size of the dispersed (Mg, Al)₂Ca             is “e”, wherein “e” satisfies the following equation (6).             1 nm≤e≤2 μm  (6)     -   [6] The magnesium alloy according to any one of the above [1] to         [5],         -   wherein a volume fraction of region of the dispersed (Mg,             Al)₂Ca is “f”%, wherein “f” satisfies the following equation             (7).             35≤f≤65  (7)     -   [7] The magnesium alloy according to any one of the above [1] to         [6],         -   wherein an ignition temperature of the magnesium alloy is             850° C. or more.     -   [8] The magnesium alloy according to any one of the above [1] to         [7],         -   wherein the “a” and “b” satisfy the following equations (1′)             and (2′).             4≤a≤6.5  (1′)             7.5≤b≤11  (2′)     -   [9] The magnesium alloy according to the above [8],         -   wherein the “a” and “b” satisfy the following equation (3′).             11/7≤b/a≤12/5  (3′)     -   [10] The magnesium alloy according to the above [8] or [9],         -   wherein an ignition temperature of the magnesium alloy is             1090° C. or more.     -   [11] The magnesium alloy according to any one of the above [1]         to [10],         -   wherein when compression yield strength is “g” and tensile             yield strength is “h”, “g” and “h” of the magnesium alloy             satisfy the following equation (8).             0.8≤g/h  (8)     -   [12] The magnesium alloy according to any one of the above [1]         to [11],         -   wherein the magnesium alloy contains at least one element             selected from the group consisting of Mn, Zr, Si, Sc, Sn,             Ag, Cu, Li, Be, Mo, Nb, W and a rare-earth metal in an             amount of “i” atomic %, where “i” satisfies the following             equation (9).             0<i≤0.3  (9)     -   [13] The magnesium alloy according to any one of the above [1]         to [12],         -   wherein the magnesium alloy contains at least one compound             selected from the group consisting of Al₂O₃, Mg₂Si, SiC, MgO             and CaO in an amount of “j” atomic % as an amount of metal             atom in the compound, where “j” satisfies the following             equation (10).             0<j≤5  (10)     -   [14] A production method of a magnesium alloy, including the         steps of:         -   forming a casting product in which Ca is contained in an             amount of “a” atomic %, Al is contained in an amount of “b”             atomic %, a residual part includes a composition of Mg, (Mg,             Al)₂Ca is contained in an amount of “c” volume %, wherein             “a”, “b” and “c” satisfy the following equations (1) to (4),             by casting method, and         -   subjecting the casting product to plastic working.             3≤a≤7  (1)             4.5≤b≤12  (2)             1.2≤b/a≤3.0  (3)             10≤c≤35 (preferably 10≤c≤30)  (4)     -   [15] A production method of a magnesium alloy, comprising the         steps of:         -   forming a casting product in which Ca is contained in an             amount of “a” atomic %, Al is contained in an amount of “b”             atomic %, a residual part includes a composition of Mg, (Mg,             Al)₂Ca is contained in an amount of “c” volume %, wherein             “a”, “b” and “c” satisfy the following equations (1) to (4),             by casting method, and         -   subjecting the casting product to plastic working.             3≤a≤7  (1)             8≤b≤12  (2)             1.2≤b/a≤3.0  (3)             10≤c≤30  (4)     -   [16] A production method of a magnesium alloy, comprising the         steps of:         -   forming a casting product in which Ca is contained in an             amount of “a” atomic %, Al is contained in an amount of “b”             atomic %, Zn is contained in an amount of “x” atomic %, a             residual part includes a composition of Mg, wherein “a”, “b”             and “x” satisfy the following equations (1) to (3) and (20),             by casting method, and         -   subjecting the casting product to plastic working.             3≤a≤7  (1)             4.5≤b≤12  (2)             1.2≤b/a≤3.0  (3)             0<x≤3  (20)     -   [17] The production method of the magnesium alloy according to         the above [16],         -   wherein the casting product contains (Mg, Al)₂Ca in an             amount of “c” volume %, wherein “c” satisfies the following             equation (4).             10≤c≤35  (4)     -   [18] The production method of the magnesium alloy according to         any one of the above [14] to [17],         -   wherein the casting product contains Al₁₂Mg₁₇ in an amount             of “d” volume %, wherein “d” satisfies the following             equation (5).             0<d≤10  (5)     -   [19] The production method of the magnesium alloy according to         any one of the above [14] to [18],         -   wherein a cooling rate in forming the casting product is             1000 K/sec or less.     -   [20] The production method of the magnesium alloy according to         any one of the above [14] to [19],         -   wherein an equivalent strain in performing the plastic             working is 2.2 or more.     -   [21] The production method of the magnesium alloy according to         any one of the above [14] to [20],         -   wherein the casting product is subjected to a heat treatment             at a temperature of 400° C. to 600° C. for 5 minutes to 24             hours before performing the plastic working.     -   [22] The production method of the magnesium alloy according to         any one of the above [14] to [21],         -   wherein the “a” and “b” satisfy the following equations (1′)             and (2′).             4≤a≤6.5  (1′)             7.5≤b≤11  (2′)     -   [23] The production method of the magnesium alloy according to         the above [22],         -   wherein the “a” and “b” satisfy the following equation (3′).             11/7≤b/a≤12/5  (3′)     -   [24] The production method of the magnesium alloy according to         any one of the above [14] to [23],         -   wherein a crystal particle size of the (Mg, Al)₂Ca after the             plastic working is “e”, wherein “e” satisfies the following             equation (6).             1 nm≤e≤2 μm  (6)     -   [25] The production method of the magnesium alloy according to         any one of the above [14] to [24],         -   wherein a volume fraction of region of dispersed the (Mg,             Al)₂Ca after the plastic working is “f” %, where “f”             satisfies the following equation (7).             35≤f≤65  (7)     -   [26] The production method of the magnesium alloy according to         any one of the above [14] to [25],         -   wherein after the plastic working, the magnesium alloy is             subjected to heat treatment.     -   [27] The production method of the magnesium alloy according to         any one of the above [14] to [25],         -   wherein after the plastic working, the magnesium alloy is             subjected to solution treatment.     -   [28] The production method of the magnesium alloy according to         the above [27],         -   wherein after the solution treatment, the magnesium alloy is             subjected to aging treatment.     -   [29] The production method of the magnesium alloy according to         any one of the above [14] to [28],         -   wherein when compression yield strength is “g” and tensile             yield strength is “h”, “g” and “h” of the magnesium alloy             satisfy the following equation (8).             0.8≤g/h  (8)     -   [30] The production method of the magnesium alloy according to         any one of the above [14] to [29],         -   wherein the casting product contains at least one element             selected from the group consisting of Mn, Zr, Si, Sc, Sn,             Ag, Cu, Li, Be, Mo, Nb, W and a rare-earth metal in an             amount of “i” atomic %, where “i” satisfies the following             equation (9).             0<i≤0.3  (9)     -   [31] The production method of the magnesium alloy according to         any one of the above [14] to [30],         -   wherein the casting product contains at least one compound             selected from the group consisting of Al₂O₃, Mg₂Si, SiC, MgO             and CaO in an amount of “j” atomic % as an amount of metal             atom in the compound, where “j” satisfies the following             equation (10).             0<j≤5  (10)

By applying an aspect of the present invention, it is possible to provide a magnesium alloy having a high incombustibility, high strength and high ductility together, or a production method thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagram showing the results of subjecting the cast extruded material of Mg_(100-a-b)Ca_(a)Al_(b) alloy to the tensile test at room temperature.

FIG. 2 is a diagram showing the results of subjecting the cast extruded material of M_(100-a-b)Ca_(a)Al_(b) alloy to the tensile test at room temperature.

FIG. 3 is a structure photograph (SEM image) of the extruded material of Mg₈₅Al₁₀Ca₅ alloy.

FIG. 4 is a diagram showing the TEM image and the electron beam diffraction pattern of the (Mg, Al)₂Ca in the extruded material of Mg_(83.75)Al₁₀Ca_(6.25) alloy.

FIG. 5 is a diagram showing the phase formation and the mechanical properties of the extruded material of Mg_(100-a-b)Ca_(a)Al_(b) alloy (a: 2.5 to 7.5 at. %, b: 2.5 to 12.5 at. %).

FIG. 6 is a diagram showing a dependency of mechanical properties on the Al addition amount in the extruded material of Mg_(95-x)Al_(x)Ca₅ alloy.

FIG. 7 is a diagram showing a dependency of mechanical properties on the Ca addition amount in the extruded material of Mg_(90-x)Al₁₀Ca_(x) alloy.

FIG. 8 is a diagram showing a dependency of structure change on the Ca addition amount in the extruded material of Mg_(90-x)Al₁₀Ca_(x) alloy.

FIG. 9 is a diagram showing a dependency of mechanical properties on the extrusion ratio in the extruded material of Mg₈₅Al₁₀Ca₅ alloy.

FIG. 10 is a diagram showing the results of the mechanical properties through the tensile test of the heat-treated extruded material of Mg₈₅Al₁₀Ca₅ alloy, at room temperature.

FIG. 11 is a diagram showing a dependency of ignition temperature on the Ca addition amount in the material of Mg₈₅Al₁₀Ca₅ alloy.

FIG. 12 is a diagram showing a dependency of ignition temperature on the Ca addition amount in the material of Mg_(100-x)Ca_(x) (x=0 to 5) alloy.

FIG. 13 is a diagram showing a dependency of ignition temperature on the Zn addition amount in the material of Mg₈₉Al₁₀Ca₁Zn_(x) (x=0 to 2.0) alloy and the like.

FIG. 14 shows a structure photograph and the analytical results of the surface film of the alloy sample obtained by melting the Mg₈₅Al₁₀Ca₅ alloy in the atmosphere.

FIG. 15 is a schematic view of the surface film of the alloy sample shown in FIG. 14.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Hereinafter, the embodiments according to the present invention will be explained in detail by referring the drawings. However, the present invention is not limited to the following explanation, and a person skilled in the art can easily understand that the present invention can modify its embodiment and detail variously without departing from the gist and scope of the present invention. Therefore, the present invention should not be construed as being limited to the description of the embodiments shown in the following.

(Embodiment 1)

One embodiment of the present invention is to develop a wrought material having high strength by using a Mg—Al—Ca alloy being a magnesium alloy in which a solute element is added at a high concentration. Tensile yield strength and elongation of Mg_(83.75)Al₁₀Ca_(6.25) extruded material which is one embodiment of the present invention and which exhibits excellent mechanical properties reach 460 MPa and 3.3%, respectively, which greatly exceed properties of the conventional Mg—Al—Ca alloy casting material and wrought material.

According to the conventional study, it has been reported that, in a Mg—Al—Ca alloy, the increase in a volume fraction of a compound containing Al and Ca decreases an ductility of the alloy, resulting in exhibiting brittleness.

However, in order to aim at developing a wrought material in the region of a high concentrated composition of Al and Ca in which a volume fraction of the compound becomes high, the inventors have found that high strength and relatively large ductility can be obtained by dispersing a hard Mg—Al—Ca based ternary compound, for example, (Mg, Al)₂Ca that is C36-type compound, into a metallographic structure.

The advantage of the addition of Al to Mg is to enhance mechanical properties, to enhance corrosion resistance, and to contribute to weight saving because a specific gravity of Al is 2.70.

The advantage of the addition of Ca to Mg is to enhance incombustibility, to enhance mechanical properties, to enhance creep resistance, and to contribute to weight saving because a specific gravity of Ca is 1.55.

The magnesium alloy according to one embodiment of the present invention contains Ca in an amount of a atomic %, Al in an amount of “b” atomic % and a residue of Mg, contains (Mg, Al)₂Ca that is a C36 compound in an amount of “c” volume %, where “a”, “b” and “c” satisfy the following equations (1) to (4), and has the (Mg, Al)₂Ca dispersed therein. Meanwhile, more preferably, “a” and “b” satisfy the following equations (1′) and (2′), further more preferably “a” and “b” satisfy the following equation (3′). 3≤a≤7  (1) 4.5≤b≤12 (or 8≤b≤12)  (2) 1.2≤b/a≤3.0  (3) 10≤c≤35 (preferably 10≤c≤30)  (4) 4≤a≤6.5  (1′) 7.5≤b≤11  (2′) 11/7≤b/a≤12/5  (3′)

The reasons for limiting the contents of Al and Ca to the ranges of the aforementioned equations (1) and (2) are as follows.

When the Al content is more than 12 atomic %, a sufficient strength cannot be obtained.

When the Al content is less than 4.5 atomic %, sufficient ductility cannot be obtained.

When the Ca content is more than 7 atomic %, it is difficult to put the magnesium alloy into a solidified state and thus is difficult to perform plastic working.

When the Ca content is less than 3 atomic %, a sufficient incombustibility cannot be obtained.

In the above magnesium alloy, the component other than Al and Ca having the contents of the aforementioned ranges is magnesium, and an impurity and other element may be contained to the extent that the alloy properties are not affected. Namely, the above wording “a residue of Mg” means not only the case where the residual part is all Mg, but also the case where the residual part contains an impurity and other element to the extent that the alloy properties are not affected.

Since the above (Mg, Al)₂Ca is a hard compound, high strength can be obtained by reducing the size of the hard compound and then dispersing the compound. In other words, in order to obtain high strength, it is preferable to disperse, at a high volume fraction, the (Mg, Al)₂Ca of the hard compound in a metallographic structure. Meanwhile, the dispersion degree of the (Mg, Al)₂Ca is preferably 1/μm² or more.

In addition, the (Mg, Al)₂Ca is equiaxed crystal, and an aspect ratio of a crystal particle of the (Mg, Al)₂Ca is approximately 1.

The above magnesium alloy preferably contains A₁₂Mg₁₇ (β phase) in an amount of “d” volume %, and the “d” satisfies the following equation (5). The β phase is not necessarily an essential phase, but is inevitably generated depending on composition. 0<d≤10  (5)

Furthermore, a crystal particle size of the dispersed (Mg, Al)₂Ca as described above is “e”, and “e” may satisfy the following equation (6). 1 nm≤e≤2 μm  (6)

Moreover, when the crystal size of the (Mg, Al)₂Ca as described above is 2 μm or less, a magnesium alloy having high strength can be obtained.

However, the above equation (6) does not mean that the whole (Mg, Al)₂Ca in the magnesium alloy is not able to be highly reinforced as long as it has the crystal particle size of 2 μm or less, but means that the magnesium alloy having a high strength can be obtained if a main portion of the (Mg, Al)₂Ca has a particle size of 2 μm or less, for example, if 50 volume % or more of the (Mg, Al)₁Ca in the magnesium alloy has a particle size of 2 μm or less. Meanwhile, the reason why a main portion of the (Mg, Al)₂Ca may have a particle size of 2 μm or less is that there is a case where the (Mg, Al)₂Ca having a crystal particle size of more than 2 μm is present in the magnesium alloy.

As described above, a volume fraction of region of the dispersed (Mg, Al)₂Ca is “f”%, and the “f” preferably satisfies the following equation (7), more preferably satisfies the following equation (7′). 35≤f≤65  (7) 35≤f≤55  (7′)

In the magnesium alloy, there exist a compound-free region in which the C36-type compound is not dispersed, and a compound-dispersed region in which the C36-type compound is dispersed. This compound-dispersed region means the aforementioned region in which the (Mg, Al)₂Ca is dispersed.

The compound-dispersed region contributes to the enhancement of the strength, and the compound-free region contributes the enhancement of the ductility. Therefore, as the compound-dispersed region is larger, the strength can be increased, and as the compound-free region is larger, the ductility can be increased. Accordingly, when the volume fraction f of region of the dispersed (Mg, Al)₂Ca in the magnesium alloy satisfies the aforementioned equation (7) or (7′), the ductility can be enhanced while the high strength is maintained.

As mentioned above, by containing Ca in an amount of 3 atomic % or more in Mg, an ignition temperature of the magnesium alloy can be made 900° C. or more.

Furthermore, as described above, by containing Ca in an amount of 4 atomic % or more in Mg, an ignition temperature of the magnesium alloy can be made 1090° C. or more (boiling point or more). When an ignition temperature is a boiling point of the magnesium alloy or more, it can also be said that the magnesium alloy is substantially incombustible.

In addition, in the aforementioned magnesium alloy, when compression yield strength is g and tensile yield strength is h, “g” and “h” satisfy the following equation (8). 0.8≤g/h  (8)

Since compression yield strength/tensile yield strength of the conventional magnesium alloy is 0.7 or less, it can be said that the magnesium alloy according to the present embodiment has high strength in this regard.

Furthermore, the magnesium alloy may contain at least one element selected from the group consisting of Mn, Zr, Si, Sc, Sn, Ag, Cu, Li, Be, Mo, Nb, W and a rare-earth metal in an amount of “i” atomic %, and “i” may satisfy the following equations (9). Therefore, it is possible to improve various properties (for example corrosion resistance) while maintaining the high incombustibility, high strength and high ductility together. 0<i≤0.3  (9)

Moreover, the magnesium alloy may contain at least one compound selected from the group consisting of Al₂O₃, Mg₂Si, SiC, MgO and CaO in an amount of “j” atomic % as an amount of metal atom in the compound, where “j” may satisfy the following equations (10), more preferably satisfy the following equation (10′). Accordingly, it is possible to improve various properties while maintaining high incombustibility, high strength and high ductility together. 0<j≤5  (10) 0<j≤2  (10′)

According to the present embodiment, by dispersing a hard compound Mg—Al—Ca-based ternary compound into a metallographic structure, it is possible to enhance mechanical properties, to obtain high strength and relatively large ductility, and at the same time, to enhance incombustibility.

In addition, the magnesium alloy may include Zn in an amount of “x” atomic %, and “x” may satisfy the following equation (20). 0<x≤3 (preferably 1≤x≤3, more preferably 1≤x≤2)  (20)

By containing Zn as described above, the strength and ignition temperature can be enhanced.

(Embodiment 2)

The production method of the magnesium alloy according to one embodiment of the present invention will be explained.

At first, a casting product formed of the magnesium alloy is produced by melt-casting method. The composition of the magnesium alloy is the same as that in Embodiment 1. The casting product has the Mg—Al—Ca ternary compound the same as that in Embodiment 1, and may contain Al₁₂Mg₁₇.

Meanwhile, a cooling speed at the time of casting by the melt-casting is 1000 K/sec or less, preferably 100 K/sec or less.

Next, by subjecting the casting product having the Mg—Al—Ca ternary compound of a hard compound to plastic working, the Mg—Al—Ca ternary compound is finely dispersed, with the result that the magnesium alloy can obtain high strength and relatively large ductility and also can enhance its incombustibility. Meanwhile, an equivalent strain in performing the plastic working is preferably 2.2 or more (corresponding to an extrusion ratio of 9 or more).

Examples of the plastic working method include extrusion method, ECAE (equal-channel-angular-extrusion) processing method, rolling method, drawing and forging method, a method in which these processing are repeated, FSW processing and the like.

When performing the plastic working by extrusion, an extrusion temperature is preferably set to 250° C. or more and 500° C. or less, and a reduction in area by extrusion is set to 5% or more.

The ECAE processing method is a method in which a longitudinal direction of a sample is rotated by 90 degrees for every pass in order to introduce a uniform strain to the sample. Specifically, the ECAE processing method is a method in which the magnesium alloy cast that is a molding material is forced to be entered into a molding pore in a molding die obtained by forming the molding pore having a cross-sectional shape of L-shape, and then application of stress to the magnesium alloy cast particularly by the part in which the L-shape molding pore is bended at 90 degrees gives a molded article having excellent strength and toughness. A number of the passes of the ECAE is preferably 1 to 8 passes, more preferably 3 to 5 passes. A temperature at the time of processing of the ECAE is preferably 250° C. or more and 500° C. or less.

When performing the plastic working by rolling, it is preferable that a rolling temperature is set to 250° C. or more and 500° C. or less, and a draft is set to 5% or more.

When performing the plastic working by drawing, it is preferable that a temperature at the time of the drawing is 250° C. or more and 500° C. or less, and a reduction in area of the drawing is 5% or more.

When performing the plastic working by forging, it is preferable that a temperature at the time of forging processing is 250° C. or more and 500° C. or less, and a processing rate of the forging processing is 5% or more.

As explained above, since the hard compound is finely dispersed in the plastic-worked article obtained by subjecting the magnesium alloy to the plastic working, the mechanical properties such as strength and ductility can be enhanced drastically in comparison with those of before the plastic working.

In addition, before the above plastic working, the casting product may be subjected to a heat treatment at a temperature of 400° C. to 600° C. for 5 minutes to 24 hours. The ductility can be increased by the heat treatment.

A crystal particle size of the (Mg, Al)₂Ca in the magnesium alloy after the plastic working is “e”, and “e” may satisfy the following equation (6). In this way, when the crystal size is 2 μm or less, a highly strong magnesium alloy can be obtained. 1nm≤e≤2μm  (6)

Furthermore, a volume fraction of region of the dispersed (Mg, Al)₂Ca in the magnesium alloy after the plastic working is “f” %, and “f” may satisfy the following equation (7), and “f” may more preferably satisfy the following equation (7′). 35≤f≤65  (7) 35≤f≤55  (7′)

The volume fraction f of region of the dispersed (Mg, Al)₂Ca in the magnesium alloy satisfies the above equation (7) or (7′), and thus it is possible to enhance the ductility while maintaining the high strength.

Moreover, when compression yield strength is “g” and tensile yield strength is “h”, the “g” and “h” of the magnesium alloy after the above plastic working may satisfy the following equation (8). 0.8≤g/h  (8)

In addition, after the above plastic working, the magnesium alloy may be subjected to heat treatment at a temperature of 175° C. to 350° C. for 30 minutes to 150 hours. Thereby, precipitation strengthening occurs to thereby increase hardness.

In addition, after the plastic working, the magnesium alloy may be subjected to a solution treatment at a temperature of 350° C. to 560° C. for 30 minutes to 12 hours. Thereby, a solid solution of a solute element, into a mother phase, which is required for the formation of a precipitate is promoted.

Furthermore, after the solution treatment, the magnesium alloy may be subjected to an aging treatment at a temperature of 175° C. to 350° C. for 30 minutes to 150 hours. Thereby, precipitation strengthening occurs to thereby increase hardness.

(Embodiment 3)

The magnesium alloy according to this embodiment is obtained by preparing a magnesium alloy material having the Mg—Al—Ca ternary compound in the same way as that in Embodiment 2, by producing a plurality of chip-like cut articles of some mm or less square produced by cutting the magnesium alloy material, and then by solidifying the cut articles through application of shear. As the solidifying method, there may be employed, for example, a method of packing the cut article into a can, of pushing the cut article by using a stick member having the same shape as the inner side shape of the can, and of solidifying the cut articles through application of shear.

In the present embodiment, the same effects as those in Embodiment 2 can be obtained.

Furthermore, the magnesium alloy obtained by solidifying the chip-like cut article is a magnesium alloy having higher strength and higher ductility than a magnesium alloy without cutting and solidification. Moreover, the magnesium alloy obtained by solidifying the cut article may be subjected to plastic working.

Meanwhile, the magnesium alloys according to the above Embodiments 1 to 3 can be used as parts used under a high temperature atmosphere such as parts for airplanes, parts for cars, particularly piston, valve, lifter, tappet, sprocket for internal-combustion engine, etc.

EXAMPLE

(Production of Samples)

First, ingots (casted material) such as Mg_(100-a-b)Ca_(a)Al_(b) alloy (a: 2.5 to 7.5 at. %, b: 2.5 to 12.5 at. %) having the compositions shown in Table 1 are produced by a high-frequency induction melting in an Ar gas atmosphere, and then extrusion billets are prepared by cutting these ingots into a shape of ϕ29×65 mm. Consequently, the extrusion billets are subjected to the extrusion processing under the conditions shown in Table 1. The extrusion processing was performed in an extrusion ratio of 5, 7.5, 10, at an extrusion temperature of 523 K, 573 K, 623 K, at an extrusion speed of 2.5 mm/sec.

(Mechanical Properties of Cast Extruded Material)

A tensile test and a compression test were performed at room temperature, with respect to the cast extruded material of Mg_(100-a-b)Ca_(a)Al_(b) alloy and the like which were subjected to the above extrusion processing. The results are shown in Table 1, FIG. 1 and FIG. 2. Meanwhile, “*” in FIG. 1 and FIG. 2 indicates elastic region breaking. In the tensile properties of Table 1, YS indicates 0.2% tensile yield strength, UTS indicates tensile strength, and in the compression properties of Table 1, YS indicates 0.2% compression yield strength, UTS indicates compression strength.

TABLE 1 Mechanical properties Extrusion condition Extrusion ratio Tensile properties Compression properties Extrusion Equivalent strain Elon- Elon- Alloy composition temperature being in YS UTS gation YS UTS gation (at %) (K) the parenthesis (MPa) (MPa) (%) (MPa) (MPa) (%) Mg87.5—Al10—Ca2.5 523 10 (2.3) 258 350 7.8 Mg86.25—Al10—Ca3.75 523 10 (2.3) 282 342 2.8 Mg85—Al10—Ca5 523 10 (2.3) 412 459 3.3 395 Interrupted in >10 the middle (Interrupted in the middle)  7.5 (2.01) 338 379  1.24  5 (1.61) 348 425  1.72 Mg83.75—Al10—Ca6.25 523 10 (2.3) 460 495 3.3 441 562 5.6 Mg82.5—Al10—Ca7.5 523 10 (2.3) Elastic 430 Elastic region region breaking breaking Mg95—Al2.5—Ca2.5 523 10 (2.3) 413 487 1.8 Mg92.5—Al5—Ca2.5 523 10 (2.3) 305 437 3.5 Mg90—Al7.5—Ca2.5 523 10 (2.3) 286 364 5.8 Mg87.5—Al7.5—Ca5 523 10 (2.3) 423 447 1.2 Mg83.75—Al11.25—Ca5 523 10 (2.3) 460 395  1.38 Mg82.5—Al12.5—Ca5 523 10 (2.3) 305 377 5.6 Mg85—Al8.75—Ca6.25 523 10 (2.3) Elastic 415 Elastic region region breaking breaking Mg87.5—Ca4.5—Al8 523 10 (2.3) 357 431 1.8 Mg87—Ca5—Al8 523 10 (2.3) 411 487 1.6 Mg86.75—Ca5—Al8.25 523 10 (2.3) 373 415 0.9 Mg86—Ca5—Al9 523 10 (2.3) 364 418 1   Mg84—Ca8—Al8 523 10 (2.3) Impossible to extrude 573 10 (2.3) Impossible to extrude Mg83.85—Ca8—Al8—Mn0.15 523 10 (2.3) Impossible to extrude 573 10 (2.3) Impossible to extrude 623 10 (2.3) Impossible to extrude Mg85—Al8—Ca7 523 10 (2.3) Impossible to extrude 573 10 (2.3) Elastic — Elastic region region breaking breaking Mg85—Al7.5—Ca7.5 523 10 (2.3) Impossible to extrude 573 10 (2.3) Elastic — Elastic region region breaking breaking Mg77.5—Al15—Ca7.5 523 10 (2.3) Impossible to extrude 573 10 (2.3) 387 426  0.77

The first composition region which is enclosed by a thick line and hatched as shown in FIG. 1 indicates a magnesium alloy in which Ca is contained in an amount of “a” atomic %, Al is contained in an amount of “b” atomic %, a residual part includes a composition of Mg, and “a” and “b” satisfy the following equations (1) to (3). 3≤a≤7  (1) 4.5≤b≤12  (2) 1.2≤b/a≤3.0  (3)

The second composition region which is enclosed by a thick line and hatched as shown in FIG. 2 indicates a magnesium alloy in which the above “a” and “b” satisfy the following equations (1′) to (3′). 4≤a≤6.5  (1′) 7.5≤b≤11  (2′) 11/7≤b/a≤12/5  (3′)

In FIG. 1 and FIG. 2, the 0.2% tensile yield strength (MPa) and the ductility (hereinafter abbreviating as δ) of enclosed the cast extruded material of Mg_(100-a-b)Ca_(a)Al_(b) alloy are shown in a ternary system strength diagram. In FIG. 1 and FIG. 2, one that is more than 5% is indicated as a white circle, one that is more than 2% and 5% or less is indicated as a gray circle, and one that is 2% or less is indicated as a black circle.

It has been confirmed that, in order to obtain the magnesium alloy exhibiting mechanical properties of high strength and high ductility, it is preferable to be within the first composition range shown in FIG. 1, and it is more preferable to be within the second composition range shown in FIG. 2. Furthermore, as shown in FIG. 1 and FIG. 2, it is found that the alloy group in which the addition amount of Al is 10 atomic % exhibits high strength and ductility.

Moreover, as shown in Table 1, it has been confirmed that a ratio of compression yield strength/tensile yield strength is 0.8 or more.

(Structural Observation of Cast Extruded Material)

In FIG. 3, a structure photograph (SEX image) of the Mg₈₅Al₁₀Ca₅ alloy extruded material among the samples produced according to the above method. In the Mg₈₅Al₁₀Ca₅ alloy extruded material, it is observed that the (Mg, Al)₂Ca (C36-type compound) is effectively dispersed, and the (Mg, Al)₂Ca is dispersed at a high volume fraction into the metallographic structure.

Among the samples produced according to the above method, from the SEM image of the Mg_(100-a-b)Ca_(a)Al_(b) alloy extruded material in the first composition range shown in FIG. 1, it has been confirmed that the volume fraction of region of the dispersed (Mg, Al)₂Ca is 35% or more and 65% or less, and it has been confirmed that the Mg_(100-a-b)Ca_(a)Al_(b) alloy extruded material having more excellent mechanical properties (high strength and high ductility) has a volume fraction of 35% or more and 55% or less.

Furthermore, among the samples produced according to the above method, a degree of dispersion of the (Mg, Al)₂Ca is observed from the SEM image of the Mg_(100-a-b)Ca_(a)Al_(b) alloy extruded material in the first composition range shown in FIG. 1, and as a result, it has been confirmed that the degree of dispersion is approximately 1/μm² or more. Moreover, among the samples produced according to the above method, an aspect ratio of the (Mg, Al)₂Ca crystal particles is observed from the SEM image of the Mg_(100-a-b)Ca_(a)Al_(b) alloy extruded material in the first composition range shown in FIG. 1, and as a result, it has been confirmed that the aspect ratio is approximately 1 and the particles are equiaxed crystals.

In addition, among the samples produced according to the above method, it has been confirmed that an upper limit of the crystal size of the (Mg, Al)₂Ca is 2 μm from the SEM image of the Mg_(100-a-b)Ca_(a)Al_(b) alloy extruded material in the first composition range shown in FIG. 1.

FIG. 4 shows a TEM image and the electron beam diffraction pattern of the (Mg, Al)₂Ca in the extruded material of Mg_(83.75)Al₁₀Ca_(6.25) as alloy among the samples produced according to the above method.

As shown in FIG. 4, the presence of the (Mg, Al)₂Ca can be confirmed by TEM, and it has been confirmed that the compound is (Mg, Al)₂Ca.

Furthermore, among the samples produced according to the above method, many (Mg, Al)₂Ca crystal sizes each having 10 nm or less are observed from the TEM image of the Mg_(100-a-b)Ca_(a)Al_(b) alloy extruded material in the first composition range shown in FIG. 1, and it is observed that the lower limit is 1 nm.

FIG. 5 is a diagram showing the formed phase and the mechanical properties of the extruded material of Mg_(100-a-b)Ca_(a)Al_(b) alloy (a: 2.5 to 7.5 at. %, b: 2.5 to 12.5 at. %).

According to FIG. 5, in the first composition range shown in FIG. 1 and the second composition range shown in FIG. 2, it has been confirmed that there exist a range in which the (Mg, Al)₂Ca is formed and a range in which the (Mg, Al)₂Ca and Al₁₂Mg₁₇ are formed.

In addition, by measurement of the formed phases, it has been confirmed that the magnesium alloy within the first composition range shown in FIG. 1 contains the (Mg, Al)₂Ca in an amount of 10% by volume or more and 35% by volume or less, and the Al₁₂Mg₁₇ of 0% by volume or more and 10% by volume or less.

FIG. 6 is a diagram showing a dependency of mechanical properties on the Al addition amount in the extruded material of Mg_(95-x)Al_(x)Ca₅ alloy, and the horizontal axis indicates an Al content x and the vertical axis indicates 0.2% tensile yield strength YS.

As shown in FIG. 6, it has been confirmed that when the Al addition amount is more than 12 atomic %, the 0.2% tensile yield strength is drastically decreased, and it is found that the upper limit of the Al addition amount is preferably 12 atomic %, more preferably 11 atomic %.

FIG. 7 is a diagram showing a dependency of mechanical properties on the Ca addition amount in the extruded material of Mg_(90-x)Al₁₀Ca_(x) alloy, and the horizontal axis indicates a Ca content x and the vertical axis indicates a 0.2% tensile yield strength YS.

As shown in FIG. 7, it has been confirmed that when the Ca addition amount is more than 3.75 atomic %, the 0.2% tensile yield strength is drastically increased. Furthermore, it is found that, when the Ca addition amount is 6.25 atomic %, the highest strength is observed, and when Ca is added in an amount of 7.5 atomic % or more, ductility cannot be observed, and the extruded material is broken in elastic limit. Therefore, it has been confirmed that the upper limit of the Ca addition amount is preferably 7 atomic %.

FIG. 8 is a diagram showing a dependency of structure change on the Ca addition amount in the extruded material of Mg_(90-x)Al₁₀Ca_(x) alloy, and the horizontal axis indicates a Ca content x and the vertical axis indicates the dispersion region of a compound or the volume fraction of a compound.

As shown in FIG. 8, it is found that the β phase (Al₁₂Mg₁₇) indicated by “▪” is within the range of 0 to 10% as a result of the measurement in a state of casting, that the C36-type compound ((Mg, Al)₂Ca) indicated by “□” is within the range of 10 to 30% as a result of the measurement in a state of casting, and a volume fraction of the dispersion region of compound (C36-type compound and the dispersion region of the β phase) indicated by “●” is within the range of 25 to 65% as a result of the measurement in the extruded material. Meanwhile, it can be said that the volume fraction of the dispersion region of the compound is preferably within the range of 35 to 65%, except for the magnesium alloy having a YS of 300 MPa or less.

According to FIG. 7 and FIG. 8, it has been confirmed that as the content of the C36-type compound becomes larger, the 0.2% tensile yield strength is increased.

FIG. 9 is a diagram showing a dependency of mechanical properties on the extrusion ratio in the extruded material of Mg₈₅Al₁₀Ca₅ alloy, and the horizontal axis indicates the extrusion ratio, the left-hand vertical axis indicate the tensile strength UTS and the 0.2% tensile yield strength σ_(0.2), and the right-hand vertical axis indicates the elongation δ.

As shown in FIG. 9, it has been confirmed that an elongation of 2% or more can be obtained by extrusion-processing at an extrusion ratio of 9 or more (equivalent strain of 2.2 or more).

FIG. 10 is a diagram showing the results obtained by evaluating, through the tensile test at room temperature, the mechanical properties of the extruded material obtained by heat-treating the Mg₈₅Al₁₀Ca₅ alloy cast at a temperature of 793 K for 1 hour, 0.5 hour, and 2 hours, and then by extrusion-processing at an extrusion ratio of 10 and at an extrusion speed of 2.5 mm/sec at a temperature of 523 K, and the horizontal axis indicates the heat-treating period of time, the left-hand vertical axis indicate the tensile strength σ_(UTS) and the 0.2% tensile yield strength σ_(0.2), and the right-hand vertical axis indicates the elongation δ.

As shown in FIG. 10, the elongation can be enhanced drastically by subjecting the casting product to heat treatment before the plastic working. Meanwhile, it is expected that the effect of the enhancement of elongation can be achieved by heat treatment for about 5 minutes.

FIG. 11 is a diagram showing a dependency of ignition temperature on the Ca addition amount in the material of alloys in which Ca is contained in an AZ91-based alloy in an amount of 0 to 3.1 atomic % in accordance with ASTM Standard (Ca-containing AZ91-based Alloys) and Mg₈₅Al₁₀Ca₅ alloy, and the horizontal axis indicates a Ca addition amount and the vertical axis indicates an ignition temperature.

According to the combustion test in FIG. 11, it is found that when the Ca addition amount is 3 atomic % or more, the ignition temperature becomes 1123 K (850° C.) or more, and when the Ca addition amount is 5 atomic % or more, the ignition temperature becomes 1363 K (1090° C.) or more.

FIG. 12 is a diagram showing a dependency of ignition temperature on the Ca addition amount in each of Mg_(100-x)Ca_(x) (x=0 to 5) alloy, Mg₉₀Al₁₀Ca_(x) (x=0 to 5) alloy, Mg_(89.5-x)Al₁₀Ca_(x)Zn_(0.5) (x=0 to 5) alloy, Mg_(89-x)Al₁₀Ca_(x)Zn₁ (x=0 to 5) alloy, and Mg_(88-x)Al₁₀Ca_(x)Zn₂ (x=0 to 5) alloy, and the horizontal axis indicates a Ca addition amount and the vertical axis indicates an ignition temperature.

According to the combustion test in FIG. 12, it is found that as the Zn addition amount becomes larger, the ignition temperature becomes high.

FIG. 13 is a diagram showing a dependency of ignition temperature on the Zn addition amount in each of Mg_(89-x)Al₁₀Ca₁Zn_(x) (x=0 to 2.0) alloy, Mg_(88-x)Al₁₀Ca₂Zn_(x) (x=0 to 2.0) alloy, Mg₈₇₋₁Al₁₀Ca₃Zn_(x) (x=0 to 2.0) alloy, Mg_(86-x)Al₁₀Ca₄Zn_(x) (x=0 to 2.0) alloy, and Mg_(85-x)Al₁₀Ca₅Zn_(x) (x=0 to 2.0) alloy, and the horizontal axis indicates a Zn addition amount and the vertical axis indicates an ignition temperature.

According to the combustion test in FIG. 13, it is found that, when the Ca addition amount becomes larger, the ignition temperature becomes high. In addition, Mg₈₃Al₁₀Ca₅Zn₂ alloy exhibits an ignition temperature of 1380 K. Furthermore, as a result of measuring the mechanical properties of the Mg₈₃Al₁₀Ca₅Zn₂ alloy produced according to the same way as in the sample shown in Table 1, it has been confirmed that a yield stress is 380 MPa.

FIG. 14 shows a structural photograph and the analytical results of the surface film of the alloy sample obtained by melting the Mg₈₅Al₁₀Ca₅ alloy in the atmosphere.

FIG. 15 is a schematic view of the surface film of the alloy sample shown in FIG. 14.

<Mechanism of Expression of Incombustibility>

According to FIG. 14 and FIG. 15, it is found that the surface film formed at melting of the Mg₈₅Al₁₀Ca₅ alloy has a three-layered structure, and the surface film is formed of an ultra-fine particle CaO layer, a fine particle MgO layer, a coarse particle MgO layer in this order from the surface layer. It is suggested that the formation of the ultra-fine particle CaO layer at the time of melting greatly contributes to the expression of incombustibility.

(Corrosion Test)

A corrosion test was carried out with respect to the magnesium alloy of the composition shown Table 2. As to a corrosion condition, a corrosion speed was measured by immersion into a 1 wt % NaCl aqueous solution (initial pH=6.8). The results are shown in Table 2.

TABLE 2 Corrosion condition: Immersion into a 1 wt % NaCl aqueous solution (initial pH = 6.8) Corrosion Composition [at. %] speed [mm/year] Mg₈₅Ca₅Al₁₀ 2.85 Mg₉₀Al₁₀ 6.04 Mg₉₅Ca₅ 10.1 Mg_(84.9)Al₁₀Ca₅Zn_(0.1) 1.57 Mg_(84.9)Al₁₀Ca₅Mn_(0.1) 0.26 Mg_(84.9)Al₁₀Ca₅Zr_(0.1) 22.95 Mg_(84.9)Al₁₀Ca₅Y_(0.1) 9.012 Mg_(84.9)Al₁₀Ca₅La_(0.1) 4.78 Mg_(84.9)Al₁₀Ca₅Ce_(0.1) 11.44 Mg_(84.9)Al₁₀Ca₅Nd_(0.1) 22.2

According to Table 2, the Mg_(84.9)Al₁₀Ca₅Mn_(0.1) alloy and Mg_(84.4)Al₁₀Ca₅Zn_(0.1) alloy which are obtained by adding a very small amount of Mn and Zn exhibit extremely high corrosion resistance. 

The invention claimed is:
 1. A magnesium alloy: comprising Ca in an amount of “a” atomic %, Al in an amount of “b” atomic % and a residue of Mg, comprising (Mg, Al)₂Ca in an amount of “c” volume %, wherein “a”, “b” and “c” satisfy the following equations (1) to (4), and having said (Mg, Al)₂Ca dispersed therein, wherein a volume fraction of region of said dispersed (Mg, Al)₂Ca is “f” %, wherein “f” satisfies the following equation (7), wherein said (Mg, Al)₂Ca is dispersed in a metallographic structure, and wherein the region contains the metallographic structure 3≤a≤7  (1) 4.5≤b≤12  (2) 1.2≤b/a≤3.0  (3) 10≤c≤35  (4) 35≤f≤65  (7).
 2. A magnesium alloy: comprising Ca in an amount of “a” atomic %, Al in an amount of “b” atomic % and a residue of Mg, comprising (Mg, Al)₂Ca in an amount of “c” volume %, wherein “a”, “b” and “c” satisfy the following equations (1) to (4), and having said (Mg, Al)₂Ca dispersed therein, wherein a volume fraction of region of said dispersed (Mg, Al)₂Ca is “f” %, wherein “f” satisfies the following equation (7), wherein said (Mg, Al)₂Ca is dispersed in a metallographic structure, wherein the region contains the metallographic structure 3≤a≤7  (1) 8≤b≤12  (2) 1.2≤b/a≤3.0  (3) 10≤c≤35  (4) 35≤f≤65  (7).
 3. The magnesium alloy according to claim 1, wherein said magnesium alloy further comprises Zn in an amount of “x” atomic %, wherein “x” satisfies the following equation (20) 0<x≤3  (20).
 4. The magnesium alloy according to claim 1, wherein said magnesium alloy further comprises Al₁₂Mg₁₇ in an amount of “d” volume %, wherein “d” satisfies the following equation (5) 0<d≤10  (5).
 5. The magnesium alloy according to claim 1, wherein a crystal particle size of said dispersed (Mg, Al)₂Ca is “e”, wherein “e” satisfies the following equation (6) 1nm≤e≤2μm  (6).
 6. The magnesium alloy according to claim 1, wherein an ignition temperature of said magnesium alloy is 850° C or more.
 7. The magnesium alloy according to claim 1, wherein said “a” and “b” satisfy the following equations (1′) and (2′) 4≤a≤6.5  (1′) 7.5≤b≤11  (2′).
 8. The magnesium alloy according to claim 7, wherein said “a” and “b” satisfy the following equation (3′) 11/7≤b/a≤12/5  (3′).
 9. The magnesium alloy according to claim 7, wherein an ignition temperature of said magnesium alloy is 1090° C. or more.
 10. The magnesium alloy according to claim 1, wherein when compression yield strength is “g” and tensile yield strength is “h”, “g” and “h” of said magnesium alloy satisfy the following equation (8) 0.8≤g/h  (8).
 11. The magnesium alloy according to claim 1, wherein said magnesium alloy contains at least one element selected from the group consisting of Mn, Zr, Si, Sc, Sn, Ag, Cu, Li, Be, Mo, Nb, W and a rare-earth metal in an amount of “i” atomic %, where “i” satisfies the following equation (9) 0<i≤0.3  (9).
 12. The magnesium alloy according to claim 1, wherein said magnesium alloy contains at least one compound selected from the group consisting of A1 ₂O₃, Mg₂Si, SiC, MgO and CaO in an amount of “j” atomic % as an amount of metal atom in the compound, where “j” satisfies the following equation (10) 0<j≤5  (10). 